Method of making padded cover board structure

ABSTRACT

The cover board structure is made with a single or multi-ply cover board, an overlying strip of paper secured to the cover board and a strip of padding disposed between the paper and the cover board. The cover board is cut from a stream of cover board structure to predetermined sizes.

United States Patent Leewood C. Carter Warren Township;

Edward K. Mullen, Westiield, both of NJ. 818,921

Apr. 24, 1969 Dec. 21 197 1 Book Covers, lnc.

Newark, NJ.

lnventors Appl. No. Filed Patented Assignee METHOD OF MAKING PADDED COVER BOARD STRUCTURE 7 Claims, 5 Drawing Figs.

US. Cl 156/204, 156/216 1nt.Cl B321) 3/04, B311 1/00 Field of Search 156/202,

[56] References Cited UNITED STATES PATENTS 2,576,121 11/1951 Kamborian 156/216 2,696,865 12/1954 Seiler 156/202 3,271,051 10/1966 Mullen et al.... 281/29 3,383,262 5/1968 Ettore et al. 156/216 Primary ExaminerBenjamin A. Borchelt Assistant ExaminerG. E. Montone Attorney-Thomas M. Marshall ABSTRACT: The cover board structure is made with a single or multi-ply cover board, an overlying strip of paper secured to the cover board and a strip of padding disposed between the paper and the cover board. The cover board is cut from a stream of cover board structure to predetermined sizes.

METHOD OF MAKING PADDED COVER BOARD STRUCTURE This invention relates to a method of making a padded cover board structure.

Heretofore, various structures have been known for making padded cover boards. For example, in some cases cover boards for books have been known wherein a cover is constructed of panels of cover board material, an enveloping cover and inserts of padding material between the panels and cover. The inserts serve to impart a padded feel to the book covers and are retained in place either by being glued to the panels or by being enveloped by the cover with the confines of the book. Generally, these book cover structures have been made in a fashion such that the individual pieces to be introduced into the book have been handled separately. Because of this, a substantial amount of time is needed to properly orient the various pieces for gluing or positioning purposes. Also, in some instances, the methods used to construct these book covers have relied on manual manipulation of the various pieces and thus have been further time consuming and expensive in terms of labor.

Accordingly, it is an object of the invention to provide a method of making padded book cover structures in an automated manner.

It is another object of the invention to provide a padded cover board structure which is simple to manufacture.

It is another object of the invention to provide a padded book cover structure which can be made in a relatively simple and inexpensive manner.

It is another object of the invention to provide a padded cover board structure which can be handled as a unit for incorporation into a book.

Briefly, the invention provides a method of continuously forming padded cover board structures from a stream of cover board structure material. In addition, the invention provides a padded cover board structure which is made as a unit and which can be handled as a unit for subsequent incorporation into book covers.

The method of the invention consists in generating a stream of cover board material of one or two ply material in alignment with cooperating streams of padded material and paper. The streams are generated in overlying alignment with each other so that the padded material is situated between the paper and the cover board material. In the course of the movement of the streams, the paper is folded along the opposite side edges. The folded under edges are then secured, as by gluing, to the top side of the cover board stream or to the underside of the cover board stream. The padded material which is sized of a narrower thickness than the paper so as to be disposed within the folded under edges of the paper is thus trapped between the paper and cover board material streams.

The paper and padding material are sized with respect to each other so that when the paper is secured to the cover board stream, the paper holds the padding securely in place. Thus, there is no need to glue or otherwise secure the padding material to the cover board structure as has otherwise been done in some cases. Because of this, the padding is able to give full effect to the quality of feel for which the padding is intended. In addition, the paper is able to seal the padding material to the outside of the cover board stream.

The padding material can be made out of foam material, flocked wood fiber, shredded paper, or any other suitable padding material. The paper can be made of any suitable paper material such as industrial kraft-type paper or of any other suitable materials such as open weave cloth or a finished paper or cloth having a decorative pattern thereon. In the case of open weave cloth, such can be made for subsequent dielectric heat sealing of vinyl to a polyurethane foam padding material for a later embossing operation.

After the streams of material are bonded together, for example, by an adhesive material, into an integral unit, the unitized stream is severed into predetermined lengths of padded cover board structure. The resulting structure can then be used for incorporation into various book cases. For

example, the padded cover board structure can be used for yearbooks and catalogues, photo albums, padded scrap books, diplomas, and padded book and book sets. In order to form such book cases, it is only necessary to apply a cover material about the cover board structure. For example, by placing two padded cover board structures in spaced relation on a strip of cover material and disposing a spine board unit between the padded board structures, the cover material can be folded over the edges of the cover boards and the spine board and secured thereto, as by gluing. This will form a book case for a book which possesses a padded feel.

The padded cover board structures which are provided by the invention can be readily handled in their unitized form on present day automatic equipment for case making. Further, since the cover board structures are formed with smooth surfaces and edges as well as with components which are securely held together, the automatic processing of such cover board structures in a case making operation on such automatic equipment can be carried out in a smooth uninterrupted manner to produce book cases of relatively high quality.

These and other objects and advantages of the invention will become more apparent from the following detailed description and appended claims taken in conjunction with the accompanying drawings in which:

FIG. 1 illustrates the respective positions of the material streams during formation of a padded cover board structure according to the method of the invention;

FIG. 2 illustrates a cross section of a completed cover board structure according to the method of the invention;

FIG. 3 illustrates a cross section of a modified padded cover board structure made according to the method of the invention;

FIG. 4 illustrates a cross section of another modified padded cover board structure made according to the invention; and

FIG. 5 illustrates a book case incorporating a pair of padded cover board structures made in accordance with the invention.

Referring to FIGS. I and 2, in order to make a padded cover board structure 10, a stream of cover board material 11 is disposed in alignment with a stream of padding material and a stream of paper 13. These streams ll, l2, 13 are generated from rolls (not shown) of the generated material and are led from the rolls in strip form. For example, the rolls can be individually mounted in a suitable machine frame in stacked vertical alignment or in horizontally disposed alignment so long as the respective streams are aligned over each other. The respective streams are oriented with respect to each other and guided along a common path by suitable guide rolls and drive rolls, for example, in a similar arrangement to the material strips in the apparatus shown in U.S. Pat. No. 3,271,051.

The stream of padding material 12 is of a width slightly less than the width of the cover board material stream 11 and is oriented so that the side edges of the padding material stream 12 is spaced from the respective side edges of the cover board material stream 11 (FIG. 2). In addition, the stream of paper 13 is of a width greater than the width of the cover board material stream 11 so asto be folded under the cover board material stream 1 1.

Initially, the respective material streams ll, l2, 13 are generated at the same speed and are brought together into a common plane. Thereafter, as these streams continue to move suitable rollers are utilized to press the streams together into contiguous contact with each other. Thereafter, the side edges of the paper material stream 13 are folded under the cover board material stream 11 by suitable guides (not shown) disposed on the sides of the generated streams. In order to secure the folded side edges of the paper stream 13 to the cover board material stream 11, the mutual contact surfaces of either stream can be provided with a self-adhesive material or other gluing compound. For example, the adhesive material or gluing compound can be coated onto the stream or streams immediately prior to the folding under of the edges of the paper stream 13.

After the side edges of the paper stream 13 have been folded under and applied against the bottom surface of the cover board material stream 11, the respective streams can be subjected to a pressing operation, for example, by passing through the: nip of a pair of pressing rolls, wherein the folded under edges of the paper stream 13 are pressed and secured to the cover board material stream 11. The resulting stream of secured together materials is then severed into individual units of padded cover board structures (not shown).

Referring to FIG. 2, the paper stream 13 is sized relative to the cover board material stream 11 and is folded over in such a fashion that the stream of padding material 12 is tightly held between the paper stream 13 and cover board material stream 11 due to the friction therebetween. Consequently, after the units of cover board structure have been severed from the stream, the padding material 12 remains in place.

Referring to FIG. 3, wherein like reference characters have been used to indicate like components as above, the padded cover board structure 14 can be constructed so that the folded over edges of the paper material stream 13 are secured to the surface of the board material stream 11 facing the padding material stream 12 rather than the surface facing away from the padding material as above. in this regard, the guides (not shown) for folding over the edges of the paper material stream 13 are positioned at a point prior to the bringing together of the respective streams 11, i2, 13 into contiguous contact. For example, the guides can be positioned at a point to fold the edges of the paper material stream under the padding material stream 12 immediately prior to passing of the respective streams through the nip of a pair of pressing rollers. Also, a suitable means for applying adhesive or gluing compounds to the surface of the cover board material stream 11 and/or the mutual surface of the folded edges of the paper material stream 13 can be positioned between the guides and the pressing means.

It is further noted that the padded cover board structure units 14 are formed so that the padding material 12 is slightly compressed in the areas defined by the folded over edges of the paper 13.

Referring to FIG. 4, wherein like reference characters have been used to indicate like parts as above, the padded cover board structure 15 is formed of a pair of cover board material streams 11, 11'. in this regard, the cover board structure 15 is made in a similar fashion as described above with respect to FIGS. 1 and 2. In addition, a second cover board material stream 11' is generated in alignment with the other cover board material stream 11 and is applied to the bottom of the folded edges of the paper material stream 13 and cover board materiai stream 11. As above, a gluing compound or adhesive can be applied between the cover board material streams 11, 11 to bond these streams together.

Referring to FIG. in order to form a book case 16 utilizing the padded cover board units 10, a pair of such units are placed upon a flat piece of cover material 117. For example, the units H) can be placed on a piece of cover material 1.7 at a predetermined station in an automatically operated case-making machine. Next, the respective edges of the cover strip 17 are folded over the respective edges of the cover board units 10 and secured thereto as by gluing as is known in the various automatic case making machines capable of using the cover board units 10. in addition, where the units 10 are spaced apart, the folded over sections 18 of the cover material 17 are pressed against the facing portions of the cover 17 and secured thereto as by gluing. The book case 16 then can be incorporated into a book structure in the usual known manner.

It is noted that the book case 16 possesses a quality which is characterized as imparting a padded feel to the touch of a user, due to the presence of the padding material within the cover. Furthermore, this feel or touch is enhanced since the padding material is not bonded to the cover board or envelop-- ing paper of the cover board structure units but rather is disposed as a separate piece within the cover board structure. Thus, the full resiliency of the padding is allowed to be apparent to the user in handling of the structure.

It is further noted that the padded book cover structures have smooth even surfaces which further enhance the adaptibility of the unitized structures to processing into book cases in present day automated case making equipment,

The padding material stream 112 can be made of foam material, flocked wood fiber, shredded paper, or any other suitable padding material which can be generated in a stream foam and placed between the cover board material stream 11 and paper stream 13. Preferably, the padding material is such as to impart the desired characteristic of the book cover structure which is to be fabricated.

The cover board material can be of any suitable material as used in the past, such as chip board. Also, the paper material stream 13 can be made of any suitable paper or cloth material, such as kraft paper, open weave cloth, a finished paper or cloth having a decorative pattern thereon and the like. Furthermore, in the case of open weave cloth, the cloth can be made so as to permit dielectric heat sealing of a polyurethane foam padding strip to a vinyl cover material.

The invention thus provides a method which can be used to produce a relatively large number of padded cover board structures within a relative minimum of time with a minimum of manipulation of the various components or pieces of the cover board structure. Furthermore, since the individual cover board structures are severed from a continuously moving stream, the sizes or lengths of the structures can be varied to conform with the desired sizes for a subsequently fabricated book.

The invention further provides a padded cover board structure which can be manipulated as a unit without the possibility of the enveloped padding material becoming dislodged from the unit. In addition, the padded cover board structure can be incorporated into any type of book structure in which the sense or feel of the padded material is desired. For example, the book cover structure can be used in yearbooks and catalogues, photograph albums, scrapbooks, diplomas, and the like.

Further, the invention provides a method wherein the pieces of padding material are securely held in place within a book cover structure without the need for bonding the padding material to another component of structure. This not only reduces the materials necessary to construct the book cover structures, but also reduces the time involved in constructing the book cover structures, In addition, the feel of the finished book cover structure is enhanced due to the freedom of the padding material to expand.

What is claimed is:

l. A method of making a padded cover board structure comprising the steps of aligning streams of board material, padding material and paper material with each other with the padding material disposed between the board material and the paper material, and with the paper materiai being of greater width and overlapping the opposite sides of said board material and padding material,

thereafter folding the two opposite sides of the paper material inwardly thereof, and

securing the folded sides of the paper material to the board material only along the contiguous surfaces of the board material and said folded opposite sides of said paper material to hold the padding material therebetween.

2. A method as set forth in claim 1 which further comprises the step of severing the stream of secured paper material, padding material and board material into successive padded cover board structures.

3. A method as set forth in claim 1 wherein the folded sides of the paper material are secured to the surface of the board material facing the padding material.

4. A method as set forth in claim 1 wherein the folded sides of the paper material are secured to the surface of the board material facing away from the padding material.

5. A method as set forth in claim 1 wherein the stream of board material includes a pair of spaced-apart plies of mate rial and the folded sides of the paper material are secured between the plies of the board material.

6. A method as set forth in claim 5 wherein the folded sides of the paper material are simultaneously secured between the plies of board material as the plies are secured together.

7. A method of making a padded cover board structure comprising the steps of aligning individual streams of board material, padding material and paper material with each other with the padding material disposed between the board material and paper material, and with the paper material being of greater width and overlapping the opposite sides of said board material and padding material,

moving the respective streams of material at a constant rate with respect to each other, subsequently folding the opposite edges of the paper material inwardly thereof during movement of the respective streams, applying adhesive to said opposite edges of said paper material, placing the folded edges of the paper material against a surface of the board material while simultaneously holding the padding material therebetween under friction,

securing the folded edges of the paper material to the surface of the board material stream only along the contiguous surfaces of the board material stream and said folded edges of the paper material, and

subsequently severing the stream of materials into individual cover board structures wherein the severed padding material is securely held between the severed paper material and board material. 

2. A method as set forth in claim 1 which further comprises the step of severing the stream of secured paper material, padding material and board material into successive padded cover board structures.
 3. A method as set forth in claim 1 wherein the folded sides of the paper material are secured to the surface of the board material facing the padding material.
 4. A method as set forth in claim 1 wherein the folded sides of the paper material are secured to the surface of the board material facing away from the padding material.
 5. A method as set forth in claim 1 wherein the stream of board material includes a pair of spaced-apart plies of material and the folded sides of the paper material are secured between the plies of the board material.
 6. A method as set forth in claim 5 wherein the folded sides of the paper material are simultaneously secured between the plies of board material as the plies are secured together.
 7. A method of making a padded cover board structure comprising the steps of aligning individual streams of board material, padding material and paper material with each other with the padding material disposed between the board material and paper material, and with the paper material being of greater width and overlapping the opposite sides of said board material and padding material, moving the respective streams of material at a constant rate with respect to each other, subsequently folding the opposite edges of the paper material inwardly thereof during movement of the respective streams, applying adhesive to said opposite edges of said paper material, placing the folded edges of the paper material against a surface of the board material while simultaneously holding the padding material therebetween under friction, securing the folded edges of the paper material to the surface of the board material stream only along the contiguous surfaces of the board material stream and said folded edges of the paper material, and subsequently severing the stream of materials into individual cover board structures wherein the severed padding material is securely held between the severed paper material and board material. 